Split hybrid insulation structure for an appliance

ABSTRACT

An insulation structure for an appliance includes a first vacuum insulated structure having a top and downward sides extending from the top and defining a lower connection surface. A second vacuum insulated structure having a bottom and upward sides extending from the bottom and defining an upper connection surface, and an intermediate insulation structure having a top surface and a bottom surface, wherein the top surface engages the lower connection surface of the first vacuum insulated structure to define the first insulated interior, wherein the bottom surface engages the upper connection surface of the second vacuum insulated structure to define the second insulated interior, and wherein the intermediate insulation structure includes an appliance utility path within which at least one utility for the appliance is disposed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 15/254,519 filed Sep. 1, 2016, entitled SPLIT HYBRID INSULATIONSTRUCTURE FOR AN APPLIANCE, which is a continuation of U.S. patentapplication Ser. No. 14/789,303 filed Jul. 1, 2015, entitled SPLITHYBRID INSULATION STRUCTURE FOR AN APPLIANCE, now U.S. Pat. No.9,441,779, the entire disclosures of which are hereby incorporatedherein by reference.

FIELD OF THE DEVICE

The device is in the field of insulation structures for appliances, morespecifically, a multi-component hybrid insulation structureincorporating multiple insulation structures.

SUMMARY OF THE DISCLOSURE

In at least one aspect, an insulation structure for an applianceincludes a first vacuum insulated structure having a top and at leastone downward side extending from the top, a lower portion of the atleast one downward side defining a lower connection surface. The top andthe at least one downward side at least partially define a firstinsulated interior. A second vacuum insulated structure includes abottom and at least one upward side extending from the bottom, an upperportion of the at least one upward side defining an upper connectionsurface. The bottom and the at least one upward side at least partiallydefine a second insulated interior. An intermediate insulation structureincludes a top surface and a bottom surface, wherein the top surfaceengages the lower connection surface of the first vacuum insulatedstructure to further define the first insulated interior, wherein thebottom surface engages the upper connection surface of the second vacuuminsulated structure to further define the second insulated interior, andwherein the intermediate insulation structure includes an applianceutility path within which at least one utility for the appliance isdisposed, and wherein the appliance utility path is in communicationwith the first and second insulated interiors.

In at least another aspect, a first vacuum insulated structure includesa plurality of continuous sides that define an open front, an open endand an engagement surface proximate the open end, wherein the continuoussides at least partially define a first insulated interior, and whereinthe plurality of continuous sides is free of internal apertures throughthe first vacuum insulated structure. An intermediate insulationstructure includes a first surface and a second surface, wherein one ofthe first and second surfaces receives the engagement surface to furtherdefine the first insulated interior. The intermediate insulationstructure includes an appliance utility path within which at least oneutility for the appliance is disposed, and wherein the appliance utilitypath is in communication with the first insulated interior.

In at least another aspect, a method for forming an insulation structurefor an appliance includes disposing at least one utility system withinthe appliance utility path of the intermediate insulation structure, andengaging the lower connection surface of the first vacuum insulatedstructure with the top surface of the intermediate insulation structureto define the first insulated interior. The first insulated interior isin communication with the appliance utility path and the at least oneutility. The method also includes engaging the upper connection surfaceof the second vacuum insulation structure with the bottom surface of theintermediate insulation structure to define the second insulatedinterior. The second insulated interior is in communication with theappliance utility path and the at least one utility. The engagement ofthe first and second vacuum insulated structures with the intermediateinsulation structure forms a split hybrid insulation structure.

These and other features, advantages, and objects of the present devicewill be further understood and appreciated by those skilled in the artby reference to the following specification, claims, and appendeddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofthe device, will be better understood when read in conjunction with theappended drawings. For the purpose of illustrating the device, there areshown in the drawings, certain embodiment(s) which are presentlypreferred. It should be understood, however, that the device is notlimited to the precise arrangements and instrumentalities shown.Drawings are not necessary to scale.

Certain features of the device may be exaggerated in scale or shown inschematic form in the interest of clarity and conciseness.

FIG. 1 is a front perspective view of a refrigerated applianceincorporating an embodiment of the split hybrid insulation structure andshown with the doors in an open position;

FIG. 2 is an exploded perspective view of an aspect of the split hybridinsulation structure;

FIG. 3 is a cross-sectional view of the appliance of FIG. 1 taken alongline III-III and illustrated with the doors in a closed position;

FIG. 4 is an enlarged cross-sectional view of the refrigeratingappliance of FIG. 3 taken at area IV;

FIG. 5 is a top plan view of an aspect of an intermediate insulationstructure for the split hybrid insulation system;

FIG. 6 is a cross-sectional view of an appliance incorporating an aspectof the split hybrid insulation structure and including a secondintermediate insulation structure for defining a pantry compartment;

FIG. 7 is an enlarged cross-sectional view of the refrigeratingappliance of FIG. 6 taken at area VII; and

FIG. 8 is a schematic flow diagram illustrating a method for forming asplit hybrid insulation structure for an appliance.

DETAILED DESCRIPTION

Before the subject device is described further, it is to be understoodthat the device is not limited to the particular embodiments of thedevice described below, as variations of the particular embodiments maybe made and still fall within the scope of the appended claims. It isalso to be understood that the terminology employed is for the purposeof describing particular embodiments or aspects of embodiments, and isnot intended to be limiting. Instead, the scope of the present devicewill be established by the appended claims.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimit of that range, and any other stated or intervening value in thatstated range, is encompassed within the device. The upper and lowerlimits of these smaller ranges may independently be included in thesmaller ranges, and are also encompassed within the device, subject toany specifically excluded limit in the stated range. Where the statedrange includes one or both of the limits, ranges excluding either orboth of those included limits are also included in the device.

In this specification and the appended claims, the singular forms “a,”“an” and “the” include plural reference unless the context clearlydictates otherwise.

As illustrated in FIGS. 1-4, reference numeral 10 generally refers to asplit hybrid insulation structure to be disposed within an insulationcavity 12 of an appliance 14 where the insulation cavity 12 is definedbetween an inner liner 16 and an outer wrapper 18 of the appliance 14.An insulation structure 10 for the appliance 14 includes a first vacuuminsulated structure 20 having a top side 22 and at least one downwardside 24 extending from the top side 22. A lower portion 26 of the atleast one downward side 24 defines a lower connection surface 28. Thetop side 22 and the at least one downward side 24 at least partiallydefine a first insulated interior 30. A second vacuum insulatedstructure 40 includes a bottom side 42 and at least one upward side 44extending from the bottom side 42. An upper portion 46 of the at leastone upward side 44 defines an upper connection surface 48, wherein thebottom side 42 and the at least one upward side 44 at least partiallydefine a second insulated interior 50. An intermediate insulationstructure 60 includes top and bottom surfaces 62, 64. The top surface 62is configured to engage the lower connection surface 28 of the firstvacuum insulated structure 20 to further define the first insulatedinterior 30. The bottom surface 64 of the intermediate insulationstructure 60 is configured to engage the upper connection surface 48 ofthe second vacuum insulated structure 40 to further define the secondinsulated interior 50. The intermediate insulation structure 60 includesan appliance utility path 66 within which at least one utility system 68for the appliance 14 is disposed. The appliance utility path 66 isconfigured to be in communication with the first and second insulatedinteriors 30, 50.

Referring again to FIGS. 2-5, the first and second vacuum insulatedstructures 20, 40 can be formed from an insulation material 80 disposedwithin a barrier film 82 and evacuated to create an at least partial, ormore typically, substantially complete or complete vacuum within thebarrier film 82. The outer surface 84 of the first and second vacuuminsulated structures 20, 40 are hermetically sealed such that the atleast partial vacuum or greater vacuum level defined within the interior86 of the first and second vacuum insulated structures 20, 40 can bemaintained throughout manufacture, assembly and use of the appliance 14.It is contemplated that the first and second vacuum insulated structures20, 40 are manufactured such that the components of the first and secondvacuum insulated structures 20, 40 are free or substantially free ofapertures, openings, perforations, or other punctures defined throughany of the surfaces of the first and second vacuum insulated structures20, 40. Accordingly, the top and downward sides 22, 24 of the firstvacuum insulated structure 20 and the connecting joints 88 therebetweenand the bottom and upward sides 42, 44 of the second vacuum insulatedstructure 40 and connecting joints 88 therebetween form a continuoussurface 90 that, as discussed above, is free of punctures, openings,apertures, and other discontinuities defined within the first and secondvacuum insulated structures 20, 40.

According to the various alternate aspects of the disclosure, the atleast one downward side 24 can include one or more downward sides 24,and typically, three sides. Similarly, the at least one upward side 44can include one or more upward sides 44, and typically, three upwardsides 44. Additional upward and/or downward sides 44, 24 may be includedto provide for various utility systems 68 of the appliance 14.

Referring again to FIGS. 2-4, the intermediate insulation structure 60can be formed from a conventional rigid foam insulation that is free ofany outer wrapper 18 or other container. Accordingly, in variousalternate aspects of the disclosure, it is contemplated that the lowerconnection surface 28 of the first vacuum insulated structure 20 and theupper connection surface 48 of the second vacuum insulated structure 40directly engage the top and bottom surfaces 62, 64, respectively, of theintermediate insulation structure 60.

According to the various alternate aspects of the disclosure, theengagement between the intermediate insulating structure 60 and thefirst and second vacuum insulated structures 20, 40 can be asurface-to-surface engagement that is substantially free or free offasteners, adhesives, welding or other connecting method. It is alsocontemplated that the lower connection surface 28 of the firstvacuum-insulated structure 20 and/or the upper connection surface 48 ofthe second vacuum insulated structure 40 with the top and bottomsurfaces 62, 64, respectively, of the intermediate insulating structure60 can optionally include adhesives, fasteners, mechanical fasteningmechanisms, interference mechanisms or other connecting methods beyond asurface-to-surface connection.

According to various alternate aspects of the disclosure, as exemplifiedin FIG. 5, the intermediate insulation structure 60 can include anintermediate cover member 100 that defines an internal mullion volume102. In such an aspect of the disclosure, it is contemplated that aninsulating material is disposed within the internal mullion volume 102.As will be described more fully below, the appliance utility path 66 isdisposed within the intermediate insulation structure 60 such that thevarious utility systems 68 of the appliance 14 can be run throughportions of the intermediate insulation structure 60. In this manner,the internal mullion volume 102 of the intermediate insulation structure60 is made to be free or substantially free of any vacuum and is not,typically, hermetically sealed. Accordingly, the appliance utility path66 defined within the intermediate insulation structure 60 provides apath through which the various utility systems 68 can be delivered tothe first and second insulated interiors 30, 50 without having to passthrough either the first and/or second vacuum insulated structures 20,40. Therefore, the first and second vacuum insulated structures 20, 40can be maintained in a continuous or substantially continuousconfiguration and free of internal openings, holes, or other punctures.In this manner, the first and second vacuum insulated structures 20, 40are free, or substantially free, of direct engagement with the applianceutility path 66.

According to the various alternate aspects of the disclosure,manufacturing the first and second vacuum insulated structures 20, 40 tobe free of openings, apertures, or other punctures can serve to simplifythe process of making the first and second vacuum insulated structures20, 40. Additionally, because the first and second vacuum insulatedstructures 20, 40 are made to be substantially free or free ofdiscontinuous surfaces, the occurrence of imperfections in the hermeticseal of the barrier film 82 can be lessened, as fewer corners, edges,and interconnections are included within the first and second vacuuminsulated structures 20, 40. It is also contemplated that the absence ofopenings, apertures, or other punctures within the first and secondvacuum insulated structures 20, 40 can serve to increase the insulatingperformance of the first and second vacuum insulated structures 20, 40,thereby increasing the energy efficiency of the first and secondinsulated interiors 30, 50 in the appliance 14 as a whole.

According to various alternate aspects of the disclosure, theintermediate insulation structure 60 can include a non-vacuum insulatedmember through which the appliance utility path 66 can be run. It isalso contemplated that at least a portion of the intermediate insulationstructure 60 can be made from a vacuum insulated member to form anintermediate insulating structure 60 made from a plurality of componentsto form a composite structure. In such an aspect of the disclosure, theappliance utility path 66 can be run through a portion of theintermediate insulation structure 60 that is not placed under a vacuum.Such a composite construction can serve to minimize the amount of thesplit hybrid insulation structure 10 that is not placed under an atleast partial or greater vacuum, while also minimizing the occurrence ofapertures, openings, and other punctures within the various vacuuminsulated structures of the split hybrid insulation structure 10.

Referring again to FIGS. 2-4, the upward sides 44 of the second vacuuminsulated structure 40 can include a lower back wall 110 that extendsupward from the bottom side 42 of the second vacuum insulated structure40. It is contemplated that the lower back wall 110 can be set forward apredetermined distance relative to an upper back wall 112 of the firstvacuum insulated structure 20. In such an aspect of the disclosure, arear portion 114 of the intermediate insulation structure 60 extendsrearward of the lower back wall 110 to define an interstitial space 116defined between the lower back wall 110 and an outer wrapper 18 of theappliance 14. At least a portion of the appliance utility path 66 can bepositioned within the rear portion 114 of the intermediate insulationstructure 60 such that the appliance utility path 66 is in communicationwith the interstitial space 116. It is contemplated that at least aportion of the interstitial space 116 can include a machine compartment118 for housing various mechanical features of the refrigeratingappliance 14. Such mechanical features can include, but are not limitedto, compressors, condensors, expansion devices, electrical features,water delivery systems, air handling units, and other similar mechanicalfixtures. Accordingly, the various utility systems 68 of the appliance14 can include at least one of an electrical system, a data system, awireless communication system, a refrigeration system, a water or otherliquid(s) system, an air handling system and other similar systems. Itis contemplated that the interstitial space 116 defined between thelower back wall 110 and the outer wrapper 18 of the appliance 14 canextend downward from a portion of the bottom surface 64 of theintermediate insulation structure 60.

Referring again to FIGS. 2-4, the downward sides 24 of the first vacuuminsulated structure 20 can include an upper back wall 112 that canengage or substantially engage the outer wrapper 18 of the appliance 14,such that the interstitial space 116 does not extend above or does notsubstantially extend above the intermediate insulation structure 60.According to various alternate aspects of the disclosure, theinterstitial space 116 can extend both above and below the intermediateinsulation structure 60 such that the upper back wall 112 and the lowerback wall 110 of the first and second vacuum insulated structures 20,40, respectively, can be at least partially offset from the outerwrapper 18 to define portions of the interstitial space 116 for housingthe various utility systems 68 of the appliance 14.

Referring again to FIGS. 3 and 4, it is contemplated that the applianceutility path 66 of the intermediate insulation structure 60 can includea plurality of conduits that extend through portions of the intermediateinsulation structure 60. In this manner, first and second conduits 130,132 of the plurality of conduits can be placed in communication with thefirst and second insulated interiors 30, 50, respectively. According tothe various alternate aspects of the disclosure, it is also contemplatedthat the first and second conduits 130, 132 of the appliance utilitypath 66 can be used to house various portions of the utility systems 68of the appliance 14. In this manner, the utility systems 68 can bedelivered from the machine compartment 118 within the interstitial space116 and through the appliance utility path 66 for delivery to positionsat least proximate the first and second insulated interiors 30, 50.

Referring again to FIGS. 3 and 4, it is contemplated that the innerliner 16 of the appliance 14 can be offset from portions of the firstvacuum insulated structure 20, the second vacuum insulated structure 40,and/or the intermediate insulation structure 60. In this manner, theutility spaces 140 can be defined between the inner liner 16 andportions of the split hybrid insulation structure 10 for housing otherportions of the various utility systems 68 of the appliance 14. By wayof example, and not limitation, one or more of the utility spaces 140defined between the inner liner 16 and the split hybrid insulationstructure 10 can be used to house one or more evaporators and airhandlers for delivering cooling to one of the first and second insulatedinteriors 30, 50. Such utility spaces 140 can also be used to house oneor more water filters, ice makers, air handling ducts, user interfacecontrols, electrical wiring, refrigeration lines, and other supportsystems and fixtures of the various utility systems 68 of the appliance14.

As exemplified in FIGS. 2-4, it is contemplated that portions of thefirst and second vacuum insulated structures 20, 40 proximate theinterstitial space 116 and the utility spaces 140 can be at leastpartially protected through the use of a cover member 160 that extendsover a portion of the first and/or second vacuum insulated structures20, 40 to prevent damage to the first and second vacuum insulatedstructures 20, 40 that may affect the at least partial vacuum formedtherein. Such a cover member 160 may be applied to prevent punctures ofthe barrier film 82 that might affect the insulated performance of thesplit hybrid insulation structure 10.

According to various alternate aspects of the disclosure, instead of theutility spaces 140 being incorporated between the inner liner 16 andportions of a split hybrid insulation structure 10, various componentsof utility systems 68 can be set within recesses 170 defined within oralong the intermediate insulation structure 60. Accordingly, suchrecesses 170 can be placed in communication with the appliance utilitypath 66 such that components of the various utility systems 68 of theappliance 14 can be delivered to the recess 170 for operating thefixtures disposed therein. It is also contemplated that the variousfixtures of the utility systems 68 of the appliance 14 that are disposedin the location of the intermediate insulation structure 60 can bepositioned in a predetermined setting and the foam insulation of theintermediate insulation structure 60 can be sprayed or otherwisedisposed around the various fixtures of the utility systems 68 of theappliance 14. In this manner, the intermediate insulation structure 60with the various components of the utility systems 68 of the appliance14 can be pre-made for installation within the split hybrid insulationstructure 10 for manufacture within the desired appliance 14.

According to the various alternate aspects of the disclosure, a splithybrid insulation structure 10 can be used for various appliances 14that can include, but are not limited to, refrigerators, coolers,freezers, warmers, ovens, cleaning appliances, electrical equipment, andother similar appliances 14. It is also contemplated that an appliance14 incorporating an aspect of the split hybrid insulation structure 10may have only a first insulated interior 30. It is also contemplatedthat such an appliance 14 may have more than first and second insulatedinteriors 30, 50.

Referring now to FIGS. 6 and 7, an appliance 14 incorporating an aspectof the split hybrid insulation structure 10 can include a first vacuuminsulated structure 20 having a plurality of continuous sides 180 thatdefine an open front 182, an open end 184, and an engagement surface 186proximate the open end 184. The continuous sides 180 of the first vacuuminsulated structure 20 can at least partially define a first insulatedinterior 30. As discussed above, the plurality of continuous sides 180of the first vacuum insulated structure 20 are configured to be free ofinternal apertures, or other punctures or openings, through the firstvacuum insulated structure 20. The intermediate insulation structure 60can include first and second surfaces that may correspond to the top andbottom surfaces 62, 64. One of the first and second surfaces isconfigured to receive the engagement surface 186 of the vacuum insulatedstructure to further define the first insulated interior 30. Theintermediate insulation structure 60 can include the appliance utilitypath 66 within which at least one of the utility systems 68 for theappliance 14 can be disposed. The appliance utility path 66 isconfigured to be in communication with the first insulated interior 30such that the utility systems 68 are delivered through the intermediateinsulation structure 60 and not through the first vacuum insulatedstructure 20.

Referring again to FIGS. 6 and 7, it is contemplated that the splithybrid insulation structure 10 can include a second vacuum insulatedstructure 40 having a second plurality of continuous sides 190 thatdefine a second open front 192 and a second open end 194 and a secondengagement surface 196. The second plurality of continuous sides 190 ofthe second vacuum insulated structure 40 can be free of internalapertures, openings, and other punctures extending through the secondvacuum insulated structure 40. The second engagement surface 196 of thesecond vacuum insulated structure 40 is configured to engage the otherof the first and second surfaces of the intermediate insulationstructure 60 to define a second insulated interior 50. As noted above,the first and second surfaces can correspond to the top and bottomsurfaces 62, 64. As with the first insulated interior 30, the applianceutility path 66 is placed in communication with the second insulatedinterior 50.

It is also contemplated that a third vacuum insulated structure 210having a third plurality of continuous sides 212, a third open front214, at least one third open end 216 and at least one third engagementsurface 218 can be disposed within the appliance 14. The first, secondand third vacuum insulated structures 20, 40, 210 can define any one ormore of a refrigerating compartment 220, freezing compartment 222 and apantry compartment 224 within a refrigerating appliance. In such anaspect of the disclosure, a second intermediate insulation structure 226can be disposed between the third vacuum insulated structure 210 and oneof the first and second vacuum insulated structures 20, 40 to define athird insulated interior 208 that can define a pantry compartment 224 ofthe refrigerating appliance. It is also contemplated that each of theintermediate insulation structure 60 and the second intermediateinsulation structure 226 can include a portion of the appliance utilitypath 66 for delivering various portions of the utility systems 68 of theappliance 14 to the first, second and third insulated interiors 30, 50,208. In this manner, the first, second and third vacuum insulatedstructures 20, 40, 210 of the split hybrid insulation structure 10 canremain undisturbed or substantially undisturbed while the utilitysystems 68 of the appliance 14 are delivered through the intermediateinsulation structure 60 and the second intermediate insulation structure226.

It is contemplated that an area behind the third vacuum insulatedstructure 210 can also include a portion of the interstitial space 116for housing at least a portion of utility systems 68 of the appliance14, which can also provide for delivery of resources by the variousutility systems 68 of the appliance 14 to the first, second and thirdinsulated interiors 30, 50, 208. In this manner, a portion of theintermediate insulation structure 60 and/or the second intermediateinsulation structure 226 can include an interstitial portion 240 thatcan define a boundary of the interstitial space 116. In such an aspectof the disclosure, the appliance utility path 66 can be in communicationwith the interstitial space 116 through the interstitial portion 240 ofthe intermediate insulation structure 60 and/or the second intermediateinsulation structure 226.

According to the various alternate aspects of the disclosure, where thesplit hybrid insulation structure 10 is used within a refrigeratingappliance, the refrigerating appliance can take the form of any one ofseveral refrigerator configurations. Such configurations can include,but are not limited to, French door bottom mount, side-by-side, coffin,single cavity refrigerator, single cavity freezer, and other variousmulti-compartment configurations that can incorporate one or both ofheating and cooling functions.

Referring now to FIG. 5, the intermediate insulation structure 60 of thesplit hybrid insulation structure 10 can include various configurationsof the appliance utility path 66. The appliance utility path 66 can beone or more conduits that extend through the material of theintermediate insulation structure 60. It is also contemplated that theappliance utility path 66 can incorporate a cutout 250 from a portion ofthe intermediate insulation structure 60. Where a cutout 250 isimplemented, various foam insulation material 80 can be used to fill inportions of the insulation cavity 12 defined between the outer wrapper18 and the inner liner 16 to increase the insulating performance of thesplit hybrid insulation structure 10.

Referring now to FIGS. 1-4 and 8, having described the split hybridinsulation structure 10, a method is disclosed for forming a splithybrid insulation structure 10 for an appliance 14. This method 400 caninclude the step of disposing at least one utility system 68 within anappliance utility path 66 of the intermediate insulation structure 60(step 402). By placing components of the utility systems 68 of theappliance 14 within the appliance utility path 66, before installing thefirst, second and/or third vacuum insulated structures 20, 40, 210,damage to the first, second and/or third vacuum insulated structures 20,40, 210 may be minimized through the process of locating the positionsof the components of the utility systems 68 prior to adding the vacuuminsulated structures. The method can also include engaging the lowerconnection surface 28 of the first vacuum insulated structure 20 withthe top surface 62 of the intermediate insulation structure 60 to definethe first insulated interior 30 (step 404). In this manner, the firstinsulated interior 30 can be placed in communication with the applianceutility path 66 and one or more of the utility systems 68 of theappliance 14. The upper connection surface 48 of the second vacuuminsulated structure 40, according to the method 400, is also moved intoengagement with the bottom surface 64 of the intermediate insulationstructure 60 to define the second insulated interior 50 (step 406). Aswith the first insulated interior 30, the second insulated interior 50is placed in communication with the appliance utility path 66 and atleast one of the utility systems 68 of the appliance 14. It iscontemplated that the engagement of the first and second vacuuminsulated structures 20, 40 with the intermediate insulation structure60 forms or substantially forms the split hybrid insulation structure10.

According to various alternate aspects of the disclosure, it iscontemplated that the one or more utility systems 68 of the appliance 14can be installed through the intermediate insulation structure 60 afterthe first and second vacuum insulated structures 20, 40 are engaged withthe intermediate insulation structure 60. The installation of thecomponents of the utility systems 68 can be installed after formation ofthe split hybrid insulation structure 10 so long as substantial damageto the first and/or second vacuum insulated structures 20, 40 that maydamage the vacuum formed therein or negatively affect the insulatingperformance of the structures can be avoided.

Referring again to FIGS. 1-4 and 8, the method 400 also includesproviding an outer wrapper 18 and an inner liner 16 for the appliance 14(step 408). It is contemplated that the split hybrid insulationstructure 10 can be disposed between the inner liner 16 and the outerwrapper 18 (step 410). The method 400 also includes the step ofconnecting the inner liner 16 to the outer wrapper 18 to form theinsulating cavity therebetween (step 412). In this manner, the splithybrid insulation structure 10 is disposed within the insulation cavity12 and an interstitial space 116 can be defined between the first and/orsecond vacuum insulated structures 20, 40 in the outer wrapper 18. Asdiscussed above, the interstitial space 116 can at least partiallydefine the machine compartment 118 of the appliance 14.

What is claimed is:
 1. A method for forming a split hybrid insulationstructure for an appliance, the method including: engaging a firstengagement surface of a first vacuum insulated structure with one offirst and second surfaces of an intermediate insulation structure todefine a first insulated interior, wherein the first vacuum insulatedstructure includes a plurality of continuous sides that are free ofinternal apertures therethrough; disposing at least one utility withinan interstitial space at least partially defined by an outer surface ofthe first vacuum insulated structure, wherein the first vacuum insulatedstructure separates the first insulated interior from the interstitialspace; connecting the at least one utility to the first insulatedinterior via an appliance utility path that extends through theintermediate insulation structure and traverses around the firstengagement surface of the first vacuum insulated structure, wherein arear portion of the intermediate insulation structure includes aninterstitial portion, wherein one of the first and second surfaceswithin the interstitial portion defines a boundary of the interstitialspace, and wherein the appliance utility path communicates with theinterstitial space through the interstitial portion of the intermediateinsulation structure; and disposing the at least one utility within theappliance utility path of the intermediate insulation structure.
 2. Themethod of claim 1, further including a step of: engaging a second vacuuminsulated structure having a second plurality of continuous sides thatare free of internal apertures therethrough, wherein a second engagementsurface of the second vacuum insulated structure engages the other ofthe first and second surfaces of the intermediate insulation structureto define a second insulated interior, and wherein the appliance utilitypath places the interstitial space in communication with the secondinsulated interior via the intermediate insulation structure.
 3. Themethod of claim 2, wherein the appliance utility path extends throughthe intermediate insulation structure and traverses around the secondengagement surface of the second vacuum insulated structure.
 4. Themethod of claim 2, wherein the appliance utility path includes aplurality of conduits that extends through portions of the intermediateinsulation structure, wherein first and second conduits of the pluralityof conduits are in communication with the first and second insulatedinteriors, respectively.
 5. The method of claim 1, further includingsteps of: disposing the first vacuum insulated structure and theintermediate insulation structure having the appliance utility pathbetween an inner liner and an outer wrapper; and connecting the innerliner to the outer wrapper to form an insulating cavity therebetween,wherein the first vacuum insulated structure and the intermediateinsulation structure are disposed within the insulating cavity, andwherein the interstitial space is defined between the first vacuuminsulated structure and the outer wrapper.
 6. The method of claim 5,wherein the interstitial space at least partially defines a machinecompartment.
 7. The method of claim 6, wherein the interstitial spaceincludes a cover member that at least partially separates the firstvacuum insulated structure from the machine compartment, wherein aportion of the first vacuum insulated structure is disposed between theinner liner and the cover member.
 8. The method of claim 5, wherein theintermediate insulation structure is defined by a foam insulationmaterial that directly engages the first vacuum insulated structure andthe inner liner.
 9. The method of claim 1, wherein the appliance utilitypath includes at least one conduit that extends through portions of theintermediate insulation structure, wherein the at least one conduit isin communication with the first insulated interior, and wherein thefirst vacuum insulated structure is free of direct engagement with theappliance utility path.
 10. The method of claim 1, wherein theintermediate insulation structure includes an internal mullion volumeand an insulating material disposed within the internal mullion volume,and wherein the internal mullion volume is free of a vacuum.
 11. Themethod of claim 10, wherein the insulating material is a foamed-ininsulation, and wherein at least one of an ice maker and a water filterare disposed within the internal mullion volume and are at leastpartially surrounded by the foamed-in insulation.
 12. A method forforming a split hybrid insulation structure for an appliance, the methodincluding: disposing an engagement surface of a vacuum insulatedstructure in direct engagement with an intermediate insulation structureto cooperatively define an insulated interior and separate aninterstitial space from the insulated interior, wherein the vacuuminsulated structure includes a plurality of continuous sides that arefree of internal apertures therethrough; disposing at least one utilityconduit within the intermediate insulation structure and extending fromthe interstitial space to the insulated interior via an applianceutility path that extends from the interstitial space through theintermediate insulation structure and traverses around the engagementsurface of the vacuum insulated structures; disposing at least oneutility within the interstitial space that is at least partially definedby an outer surface of the vacuum insulated structure, wherein thevacuum insulated structure separates the insulated interior from theinterstitial space; connecting the at least one utility to the insulatedinterior via the at least one utility conduit; disposing the at leastone utility within the at least one utility conduit of the intermediateinsulation structure; and disposing the vacuum insulated structure andthe intermediate insulation structure having the at least one utilityconduit between an inner liner and an outer wrapper; and connecting theinner liner to the outer wrapper to form an insulating cavitytherebetween, wherein the vacuum insulated structure and theintermediate insulation structure are disposed within the insulatingcavity, and wherein the interstitial space is defined between the vacuuminsulated structure and the outer wrapper.
 13. The method of claim 12,wherein the interstitial space at least partially defines a machinecompartment.
 14. The method of claim 13, wherein the interstitial spaceincludes a cover member that at least partially separates the vacuuminsulated structure from the machine compartment, wherein a portion ofthe vacuum insulated structure is disposed between the inner liner andthe cover member.
 15. The method of claim 12, wherein the intermediateinsulation structure is defined by a foam insulation material thatdirectly engages the vacuum insulated structure and the inner liner. 16.A method for forming a split hybrid insulation structure for anappliance, the method including: disposing an engagement surface of avacuum insulated structure in direct engagement with an intermediateinsulation structure to cooperatively define an insulated interior andseparate an interstitial space from the insulated interior, wherein thevacuum insulated structure includes a plurality of continuous sides thatare free of internal apertures therethrough; disposing a utility conduitwithin the intermediate insulation structure, the utility conduitextending from the interstitial space to the insulated interior via anappliance utility path that extends from the interstitial space throughthe intermediate insulation structure and traverses around theengagement surface of the vacuum insulated structure, wherein theinterstitial space is partially defined by a cover member that at leastpartially separates the vacuum insulated structure from the interstitialspace; disposing the vacuum insulated structure and the intermediateinsulation structure having the utility conduit between an inner linerand an outer wrapper; and connecting the inner liner to the outerwrapper to form an insulating cavity therebetween, wherein the vacuuminsulated structure and the intermediate insulation structure aredisposed within the insulating cavity, and wherein the interstitialspace is defined between the vacuum insulated structure and the outerwrapper.